Composition and method for flavoring popped popcorn

ABSTRACT

A flavored, aqueous-based, adhesive composition containing no added fat or oil is sprayed onto popped popcorn, then a dry flavorant is applied, and the popcorn dried of excess moisture.

FIELD OF THE INVENTION

The present invention relates to compositions and methods for flavoringpopcorn. Methods described herein can be used to prepare flavoredkernels which can be popped by such methods as microwave popping, togenerate flavored popcorn product. Certain methods and compositionsdescribed herein can be applied to already popped popcorn, to generate aflavored "prepopped" product. Various popcorn products are alsoprovided.

BACKGROUND OF THE INVENTION

The present disclosure relates to popcorn flavoring. In general, itrelates to two applications of flavoring. The first will be referred togenerally as flavoring of "prepopped" popcorn. The second will begenerally referred to as flavoring of microwavable popcorn compositions.

I. Flavoring of Prepopped Popcorn

A variety of consumer popcorn products are generally referred to as"prepopped" products. These are popcorn products which are popped beforethey are obtained by the consumer for consumption. For example, suchproducts include bags or canisters of already popped popcorn.

In general, prepopped consumer popcorn products are provided with avariety of flavorings. These include, for example: butter/saltflavoring; cheese flavoring; and, sweet flavorings such as caramel.

Conventional approaches to flavoring prepopped popcorn have often beendeveloped based on a belief that application of flavoring through theutilization of aqueous-based materials is to be avoided. A reason forthis has been industry observations that application of waterundesirably affects the popcorn. In particular, popped popcorn flakesreadily become soggy when they encounter water.

In some instances, flavored prepopped popcorn has been generated byincluding flavorant in the oil/fat in which the popcorn is prepared. Forexample, butter/salt flavorings are sometimes provided in oil/fat inwhich the popcorn is cooked. Relatively recently, however, consumerconcerns with respect to preparation of popcorn utilizing substantialamounts of added oil or fat have been of concern. It has been preferred,therefore, to attempt flavoring approaches which do not involve the useof added oil/fat to any substantial degree.

Other methods by which prepopped popcorn has been flavored involve theaddition of flavorings in nonaqueous-based application solutions. Forexample, alcohol-based or oil-based systems have been used. Theserequire the utilization of substantial amounts of organic solvents, andprocessing techniques for removal of the solvent vapors. In addition,they are relatively expensive, due to the costs associated withprocuring and removing the organic solvents.

II. Flavored, Unpopped Popcorn Products

Freshly popped popcorn is also a popular consumer item. Such productsare typically popcorn sold in the form of unpopped kernels, which arepopped by the consumer.

In general, there have been developed two principal methods of flavoringsuch popcorn. The first is the addition of flavoring after the popcornis popped. For example, consumers often add butter and salt to freshlypopped popcorn to provide desirable flavor, aroma or color.

A second method is to provide flavorings or other materials mixed withthe unpopped kernels, so that during the popping process the kernels areprovided with flavor (or color, etc.). Such methods typically requirecontrol of the components in the flavoring mixture, to avoid undesirableburning or scorching during the popping process.

In general, techniques for providing flavorings mixed with the popcorn(prior to popping) have developed in part with specific focus on themethod to be utilized by the consumer to cause popping. That is, thedemands of the environments provided by alternate methods of popping,such as hot-air poppers, conventional heated popcorn poppers withoil/fat, or microwave systems, have to some extent dictated differentneeds or requirements in the flavoring compositions.

In some conventional popcorn poppers, flavorings are mixed in withoil/fat used during the popping process. During the popping process, theoil/fat will tend to splash over the popping popcorn, spreading theflavoring over the popped popcorn. In some systems, this has been aparticularly convenient method for providing butter/salt flavoring tothe popcorn.

Some conventional microwave popcorn systems have utilized similarprinciples. That is, the popcorn is packaged with a salt flavoring thatis mixed with an added oil/fat material. When the package is placed in amicrowave oven, the popcorn is popped in the presence of the oil/fat andthe flavoring is distributed over the popcorn. Such a system isdescribed, for example, in U.S. Pat. No. 3,704,133, the disclosure ofwhich is incorporated herein by reference. A system which utilizes afilm former in conjunction with an oil/fat to coat the popped popcornwith a flavoring material is described in U.S. Pat. No. 3,851,574,incorporated herein by reference.

In recent years, consumer focus has turned to preferences for "light","low fat", "no fat" or similar food products. In many instances,consumers prefer to prepare their foods by means other than through theutilization of substantial amounts of oil/fat in the preparationprocess. Hot-air poppers, which do not utilize substantial amounts ofoil/fat in the popping process, have enjoyed some popularity. However,in general, the provision of flavorings during the popping process,rather than added after the popping process, has been a problem.

One method developed to approach this is presented in U.S. Pat. No.4,767,635, the disclosure of which is incorporated herein by reference.According to that disclosure, the unpopped kernels are provided with afilm or coating having some flavoring material retained therein.According to the reference, during a popping process, a portion of thefilm retains some of the flavoring on residual hulls of the kernels.

With respect to microwavable popcorn products, Golden Valley MicrowaveFoods, the assignee of the present application, has developed systemsfor providing flavored microwavable popcorn kernels, and ultimately amicrowave popped flavored popcorn product, in the absence of addedoil/fat. Techniques with respect to this are described in U.S. Ser. No.08/198,892, now abandoned, the disclosure of which is incorporatedherein by reference. Further descriptions of the products from suchprocessing are described in U.S. application Ser. No. 08/391,437, filedFeb. 21, 1995, also owned by Golden Valley Microwave Foods andincorporated herein by reference. That application was filed identifyingDana S. Freeport as the inventor, and has the title: COMPOSITION ANDMETHOD FOR FLAVORING POPCORN; AND PRODUCT. Golden Valley Microwave Foodshas marketed such a product under the name "ACT II® 96% Fat-FreePopcorn". The products generally comprise coated kernels of popcorn,which are popped in a microwave bag construction, to generate a flavoredpopped popcorn product.

SUMMARY OF THE INVENTION

According to the present invention a method of applying a flavoringcomposition to flakes of prepopped popcorn is provided. The methodgenerally includes steps of applying an aqueous-based adhesivecomposition to the flakes of prepopped popcorn; and, after the step ofapplying aqueous-based adhesive composition, applying dry flavorantcomposition to the flakes of popcorn. Following this, a step of dryingis conducted, to avoid undesired loss of crispness due to excessmoisture. Preferably the method of applying the adhesive compositioncomprises applying the composition as a fine mist.

In preferred applications, the adhesive composition contains about0.5-15% by weight adhesive. The amount, however, will be varieddepending upon the particular adhesive used. Preferred ones areidentified herein.

In general the step of spraying the adhesive composition onto the flakescomprises applying about 1-10% by weight adhesive composition, perweight of popped flakes. In certain preferred applications, about 4-6%by weight is applied.

Preferably the dry flavorant composition comprises a material sized to50-250 mesh (U.S. Standard).

Also according to the present invention, a method of applying aflavoring composition to kernels of unpopped popcorn, which can bepopped in a microwave oven, is provided. The method in general comprisessteps of applying an aqueous-based adhesive composition onto unpoppedkernels of popcorn, the aqueous-based adhesive composition including aflavoring adhesive effective amount of an adhesive gum. In certainpreferred applications, the step of applying comprises applying no morethan about 2%, and typically no more than 1.4%, by weight, adhesivecomposition, per weight popcorn kernels. In general the method includesa step of applying dry flavorant composition to the kernels, after theyhave been coated with the adhesive composition. The method thengenerally concerns a step of drying the moisture from the pieces ofpopcorn.

With respect to the application to unpopped kernels, preferably the stepof applying comprises applying no more than about 1.4% (and preferablyabout 0.5-1.2%) by weight adhesive composition, based on the weight ofkernels. Also preferably for application to unpopped kernels, theadhesive composition contains no more than about 15% by weight adhesive,with a specific amount being variable depending upon the particularadhesive chosen.

Also, according to the present invention a prepopped popcorn productcomprising a result of applying flavorant in preferred manner toprepopped popcorn flakes is provided. Further, an unpopped popcornproduct comprising coated kernels which can be popped conveniently, forexample in a microwave popping process, is provided.

Further, in general, techniques are described herein for preparingflavored consumer products and for preparing products for ultimateingestion, according to the techniques described.

DETAILED DESCRIPTION OF THE INVENTION

As indicated above, the principles disclosed herein concern thepreparation of flavored, prepopped popcorn products as well as flavoredkernels from which freshly popped popcorn can be made. While techniquesaccording to the present invention, when applied in the differentcircumstances, can be similar, the two types of products and techniquesspecifically related to them will be described separately. In part, thisis because the different applications have different needs andrequirements.

I. Flavored, Prepopped Popcorn Products

In general, this application of the techniques described herein concernsfirst preparing popped popcorn, and then applying flavoring thereto. Thetechniques are particularly adapted to the provision of "low fat" or"low added fat" systems or systems in which the popcorn is at least notpopped in an oil/fat mixture. Popcorn generally inherently includesabout 4% by weight fat, and the techniques described herein do notaffect that content. In addition, it is noted that some flavorantsinclude some amounts of oil/fat therein. However, the flavorants aregenerally utilized in such small amounts that the overall fat content ofthe product is not substantially affected by the flavorant. Oil/fatadded as a result of the flavorant chosen are generally disregarded inthe descriptions of the techniques presented herein.

A. Obtaining the Prepopped Popcorn

In general, it is desired to flavor popcorn which has been popped in theabsence of oil/fat. In large volume, for prepopped, packaged, consumerproducts, such popcorn can be obtained through the utilization ofconventional hot-air poppers and conventional hot air popping methods.The popcorn typically used will be from kernels having: yellow color;approximately 65 kernels/10 gram; and a moisture of 14% by weight(13.7%-14.3%); and, which is popped to an expansion density of about39:1 to 43:1 (ratio of pop volume to unpopped volume). Beforeapplication of coating compositions to the popped popcorn according tothe present techniques, fines and unpopped kernels should preferably besifted away from the prepopped flakes of popcorn. For preferredapplication of adhesive and flavoring, the prepopped flakes would betransferred to a pan-type coater.

B. Application of the Flavoring to the Popped Popcorn

According to the techniques of the present invention, an aqueous-basedadhesive composition or tackifying composition is applied to the poppedpopcorn. After the adhesive composition is provided on the popcorn,flavorant and, optionally, various adjuvants are added as a dry mixture.

1. Preparation of the Adhesive Composition

The adhesive composition is preferably applied in the form of anaqueous-based composition. The composition is sometimes referred to as a"tacking" or "tackifying" composition. The composition is preferably asolution, rather than a suspension. Although the solution isaqueous-based, preferably it includes only about a sufficient amount ofmoisture (water) for convenient application and spread over the poppedflakes. Also, an effective amount of the adhesive (or tacking agent) toadhere the added flavorant to the popcorn, for delivery of flavor to theconsumer, should be applied (i.e. a flavoring adhesive effectiveamount). Preferably the applied composition contains about 0.5-15% byweight tacking agent or adhesive, the remainder preferably being water(or in some instances also adjuvant as described). The ratio (by weight)of the tacking agent or adhesive applied, to the dry flavoring orseasoning blend later applied, is preferably between 0.2:1 and 1:1. Thetotal weight of adhesive composition applied will preferably be about 1%to 10%, by weight, (more preferably 4-6%) of the weight of the poppedpopcorn.

A variety of tacking agents or adhesives may be used. Preferredmaterials usable as the tacking agent comprise bacterial polysaccharidegums such as gellan gum, xanthan gum, gum arabic, and cellulose gum ormixtures thereof. By "bacterial" in this context, it is meant that thegum comprises a product of a microorganism's operation on a fermentationmedium. For example, gellan gum is produced by the microorganismPseudomonas elodea (ATCC 31461). Xanthan gum comprises the fermentationproduct of Xanthomonas campestris. Gum arabic, also known as Gum acacia,is the dried gummy exudate from stems and branches of Acacia senegal(Linne), willdenow or other related African species of acacia. A useablecellulose gum is sodium carboxymethyl cellulose.

The presently preferred gum is gellan gum. A particular preferred gellangum for utilization in coating compositions for prepopped popcorn isavailable under the trade designation K3B408, from the Kelco Division ofMerck & Co., Inc., San Diego, Calif. 92193. K3B408 is a blend of gellangum and sodium citrate. The sodium citrate facilitates the hydration ofgellan gum at ambient temperatures (60°-70° F.) in tap water; thus thesodium citrate helps dispersion of the gum in tap water.

Another preferred gum for utilization in compositions for application toprepopped popcorn is a blend of maltodextin, corn syrup solids, gumacaia, and cellulose gum (the commercial product being TIC Gums No-FatSnack Blend, available from TIC Gums, Inc. of Belcom, Md.). In certainpreferred compositions, as exemplified below, mixtures of commercialK3B408 gellan gum and the commercial TIC Gums No-Fat Snack Blend will bedesired.

In general, the K3B408 and the TIC material are preferred to othercommercial gum materials due to the ease with which they can besolubilized in water at ambient temperatures and also because low usagelevels are possible (for example, K3B408 can be used at levels of 0.1-1%based on wt. of tacking composition and TIC No-Fat at levels of 7-15%based on wt. of tacking composition).

In part because of the methods of application desired, it is preferredthat the tackifying agents or adhesives used in adhesive compositionsaccording to the present invention are ones which are soluble in water;and, it is preferred that the adhesive compositions be prepared assolutions, i.e. with the gum(s) fully dissolved. It is also preferredthat the solubility be such that at least about 0.5 g to 15 g of gum canbe readily dissolved per 100 ml of water (at ambient). Usable,commercially available, gums which satisfy this requirement include thefollowing:

Kelcogel K3B408; from Kelco Division of Merck & Co., Inc., San Diego,Calif. 92193

TIC Gums No-Fat Snack Blend; from TIC Gums, Inc., Belcom, Md. 21017-0369

Gum Arabic, NF Premium, spray dried Type A-180; from GumixInternational, Fort Lee, N.J. 07024-7552

Keltrol GM, Xanthan gum; from Kelco Division of Merck & Co., Inc., SanDiego, Calif. 92193

Methocel (A4MP or K4MP) Cellulose Gum; from Dow Chemical, Midland, Mich.48674.

The adhesive compositions can be prepared by mixture at ambienttemperature. They may optionally include some flavoring and/or coloring(or other adjuvants). However, as indicated previously, it is preferredthat the adhesive compositions comprise solutions. Thus, any flavoringand/or coloring (or other adjuvants) provided should be in solution. Ingeneral, if flavorant or other adjuvant is included in the tackingsolution, it will be preferred not to include more flavoring/coloring orother adjuvants than will fully dissolve in the amount of moistureneeded to provide the adhesive in a solution form and to effectivelycoat the popped popcorn flakes. Preferably any dissolved flavorantand/or other adjuvant is at a level of about 0.1-2.0%, by weight in theadhesive solution.

Generally, when flavorants and/or other adjuvants are put in theadhesive solution, it is to enhance the performance of later addedflavor, for example salt. Applying some flavorings and adjuvants in theadhesive solution may improve the uniformity of the distribution offlavor.

2. Application of the Tacking Composition to the Popped Popcorn

Preferably the tacking solution is applied to the popped popcorn as afine mist. A variety of techniques may be utilized to generate the finemist applied to the popcorn. A device such as a Wagner Heavy Duty PowerPainter (from Wagner Tool), for example, which is capable of being setto generate a relatively fine spray mist, can be used. By "fine mist" itis meant that the spray is of droplets and is not a continuous waterstream.

With respect to application techniques, the following factors have beenobserved to be of interest, at least in part, to obtaining a desirableflavored prepopped product:

(a) Amount of water (or tacking composition) applied per weight ofpopped popcorn;

(b) Amount of adhesive applied per weight of popped popcorn;

(c) Rate of drying of moisture from the prepopped flakes, afterapplication of the adhesive composition.

In general, success in developing a well or fully flavored prepoppedpopcorn product according to the present invention has been obtainedwhen the amount of adhesive composition added to the flakes by misting,is about 1-10% of the weight of the popped flakes. In general, undesiredlevels of sogginess are achieved with additions of greater than about10%. While the amount of moisture that can tolerated will vary dependingupon the particular application technique used, and the rate of dryinginvolved, in general addition of about 4-6% of mist, per weight popcorn,with relatively even distribution, is preferred.

The amount adhesive agent that should be applied may vary depending uponthe particular adhesive chosen. However, in general, success has beenobtained with application of about 15-150 grams of adhesive composition(including water weight) per 1500 grams popcorn. Amounts which aresubstantially lower may lead to insufficient adhesive for desirableretention of flavorant during the next step. Larger amounts of adhesivemay simply require sufficient amounts of moisture and sufficiently longapplication times, that undesirable water logging of the flakes occurs.

Preferred methods and rates of drying are described in a further sectionbelow.

C. Application of Flavoring and/or Coloring (or Other Adjuvants)

Flavoring and/or coloring (other than any that may have been included inthe mist) is added as a dry blend. Preferably it is sifted onto thepopped flakes immediately after the tacking solution has been applied tothe popped flakes, and before the surfaces of the popped flakes arecompletely dried. Fine powders are preferred, for the dried blend, foreven distribution of color and/or flavor over the uneven surfaces of thepopped flakes. Thus, preferably dry mixes that are sifted to 50-240 (or50-250) mesh (U.S. Standard Mesh) are used. By this is meant that theparticles are generally smaller than 50 mesh and greater than about 240or 250 mesh.

In general, spray dried and dry encapsulated flavors are preferred, sothe flavorant itself can be blended and applied directly to the surfaceof the flake where it will yield the highest impact.

If the selected flavoring is to include salt, in general it is preferredthat a very fine grind, or powdered, salt be utilized. An acceptablesuch material is the one available under the tradename MORTON SALT 200from Morton International (Morton Salt, Chicago, Ill. 60606). Thismaterial goes through a 200 USS mesh. Another usable salt material isavailable under the designation Morton Flour, from Morton Salt. Thismaterial is 70-240 U.S.S. mesh.

In general, ordinary table salt is not preferred. Such relatively largecrystals tend not to adhere as well, when applied. This decreases thebatch yield and ultimately the amount of flavoring which is delivered tothe consumer (on the flakes).

In general, to provide a desirable salt flavor, at least about 100 g ofsalt should be applied per 1500 g popcorn.

Besides salt flavorings, a variety of alternative or additionalflavorings may be utilized. For example, in many applications apreferred flavoring mixture (for many consumers) will be a butter/saltmixture. For such a mixture, the butter flavoring can be providedthrough the utilization of artificial butter flavors. Preferred ones areEncapsulated Starter Distillate-50X (available from Chris Hanson'sLaboratories, Inc., Milwaukee, Wis. 53214), Natural Butter Flavor NF6258 Dry, also from Chris Hanson's Laboratories, and Butter Flavor,NF5048, also from Chris Hanson's Laboratories.

In some instances it may be desirable to provide a yellow dye, toprovide a desirable yellow hue to the flavored popcorn. Yellow #5,Aluminum lake or Tumeric are desirable colorants for this purpose.

Techniques according to the present invention can also be used togenerate sweetened or sweet flavored popcorn flakes. One suchcomposition is described hereinbelow. In general, preferred materialsfor forming sweetened flavor include the following artificial flavors:

Sunette, acesulfone potassium; from Hoechst Celanese, Edison, N.J. 08818

Aspartame 200; from Sanofi Bio-Industries, Fairfield, N.J. 07066.

Another popular flavor in popcorn is cheese flavor. A specific examplefor provision of a cheese flavor is provided below. In general, a cheeseflavor can be accomplished through utilization of, in addition to saltand butter flavor, commercial cheese flavors such as Tastemaker Cheeseflavors #308342, #308962 and #304558; Tastemaker, Cincinnati, Ohio.

A wide variety of other flavors or flavor enhancers can be used. Forexample, peanut flavors, yeast extracts, or similar materials areusable. Also a wide variety of spice flavors are usable, for example:herb and garlic; sour cream and onion; honey mustard; hot mustard; dryroast; barbecue; jalapeno; or Mexican. If the spices are not drypowders, so they can be dry mixed with the other flavorants/adjuvants,in general they should be supported upon a powdered base such asmaltodextrin or cornstarch. For example, Tone's dry roast seasoning(T-067) from Tone's Industrial Seasonings, Des Moines, Iowa 50301.

As indicated previously, various sweet flavorings can be utilized. Forexample: chocolate, chocolate mint, mint, chocolate banana, vanilla,pineapple, coconut, cherry and peppermint flavorings may be provided. Inmany instances these materials are liquid flavors. They may be providedeither in the solution including the adhesive, or in the dry powder byloading on to powder or mixing such that they are well dispersed withthe dry material and do not generate a sticky mess.

Other adjuvants may be included in the dry powder mix, to be sifted ontothe corn. For example, calcium chloride, which bonds upon contact withgellan gum, may be used to improve strength and speed of bonding of thecomponents of the gum.

Immediately after the application of the dry powders, a drying processof the coated kernels should be initiated, preferably by hot air drying.The drying should be conducted to remove excess moisture (preferably toprovide a moisture level no greater than about 2% by weight) and togenerate a dry crisp product. Preferably the original moisture level ofthe popped flakes (about 1.5% by weight) is restored. Air temperaturesfrom the heat sources used for the air drying will typically be withinthe range of about 200°-600° F. Relatively higher temperatures aregenerally preferred, so that the moisture is driven off as quickly aspossible to maintain the final product quality. Drying times on theorder of about 10 minutes have been used and are convenient.

D. Processing Aids

A variety of processing aids or adjuvants can be used. For example,additives which will decrease the adhesion of the popped flakes to oneanother may be desired. Such aids would include, for example, silicondioxide (Zeothix 265; J. M. Huber Corp., Etowah, Tenn. and Havre deGrace, Md.).

The finely powdered or ground flavorant mix (with or without additives)and its application in a dry form to the moist popcorn flakes, providesadvantage. In particular, the high surface area of dry mix helps drawthe moisture, as soon as the powder is applied to the flakes. Thisslows, somewhat, absorption of the moisture by the popcorn flakes, andloss of crispness in the flakes.

E. Further Observations Regarding Coating of Pre-Popped Flakes

The present water-based (or aqueous-based) system for adhesion offlavorants on the pre-popped flakes is believed desirable due in part tothe relatively high viscosity of the preferred tacking composition; theratio of the weight of the tacking solution to the weight of dryingredients (optimum ratio being approximately 2 parts tacking solutionto 3 parts dry ingredients by weight), and drying at high temperaturesto dry off moisture as quickly as possible to minimize the loss ofsurface crispness. Loss of surface crispness with exposure to water is aproblem unique to pre-popped flakes, as opposed to many other snackfoods or unpopped kernels. Due to the uneven surface of popcorn flakes,the amount of tacking solution cannot be readily reduced to much belowthe stated desired range stated without compromising adhesion of the dryflavorants (i.e. yield and flavor impact).

It is also noted that gellan gum forms a crisp film upon heating, whichimproves the final product quality. In general, fat replacer flavorswill typically be used to improve the flavor and mouth feel of the finalproduct.

II. Coated, Unpopped Kernels for Preparation of Flavored, Freshly PoppedPopcorn Products

Techniques described herein can also be used to prepare coated, unpoppedkernels from which flavored, freshly popped, popcorn products can beprepared. Thus, for example, with the techniques described herein, apackage of microwavable popcorn product can be prepared which, whenplaced in a microwave oven and appropriately exposed to microwaveenergy, will result in a freshly popped flavored popcorn product for theconsumer.

In general, the techniques are generally analogous to those used forpreparing the flavored, popped popcorn product. That is, a tackingcomposition or solution is applied to the kernels, and then flavoring isadded as a dry powder sifted onto the kernels, with follow-up drying.However, specific methods used, and amounts applied, may be variedrelative to flavoring prepopped popcorn.

A. Preferred Consumer Products Made Utilizing the Techniques DescribedHerein

Similarly to the disclosure of U.S. Ser. No. 08/198,892, the presenttechniques concern modifying microwave popcorn in such a manner that ashelf sable unpopped popcorn product is provided that can be readilypopped by exposure to microwave energy, to provide a flavored popcornwith a relatively high flavor impact. The term "high flavor impact" ismeant, in this context, to refer to popped kernels on which are retaineda substantial amount of the flavoring provided in the original unpoppedcomposition, as opposed to loss of the flavoring in processing or to thebottom of the package or bowl. That is, in these products a substantialportion of the flavoring is retained on the kernel, i.e., the hullremnant of the popped popcorn, and it does not fall off or become lostin packaging. The method is particularly developed so that flavoring canbe provided in the absence of popping with added oil/fat. Thus, exceptfor small amounts of oil/fat that may be contained in the flavoringsthemselves, the popcorn can be prepared essentially "low fat" or "fatfree". In this context, the term "fat free" and similar terms is meantto characterize the fact that the methods are developed to occur withoutadded fat or oil to facilitate popping. When the term is used, smallamounts of oil/fat in the flavorings, and fat inherent in the popcorn(about 4% by weight), are disregarded.

In general, a typical consumer product would comprise a packagecontaining microwavable popcorn, which the consumer can place in amicrowave oven and, through exposure to microwave energy, pop. Theflavor would be provided on the popcorn, without further operation bythe consumer. That is, the consumer need only open the bag to consumethe flavored popcorn. The bag need not be shaken to distribute flavor,and the flavor will generally be well adhered to the hulls of the poppedpopcorn. The popcorn may be popped utilizing conventional bagconstructions for microwave popcorn, such as those described in U.S.Pat. Nos. 4,450,180; 4,548,826; 4,691,374; and 5,044,777, incorporatedherein by reference. The arrangements described in the U.S. applicationassigned provisional Ser. No. 08/389,755, filed Feb. 15, 1995,incorporated herein by reference, may also be used. It was filed withthe title: IMPROVED MICROWAVE COOKING CONSTRUCTION FOR POPPING CORN,with Robert H. Blamer and Denise E. Hanson identified as the inventors.It is owned by Golden Valley Microwave Foods, Inc.

While variations are possible, in a typical consumer product about 83grams (approximately 515 kernels) of microwave popcorn are provided in asingle pouch or bag construction. Such an amount of popcorn generallywill pop to a volume of about 2700 to 3000 ml.

In general, flavored, unpopped, kernels made according to the presentprinciples, similarly to kernels made according to the principlesdescribed in U.S. Ser. No. 08/198,982, demonstrate a loss of coating,for a 225 gram, coated, unpopped, popcorn sample, after prepared andwhen tested according to procedure such as that described herein withrespect to prepopped flaking evaluation, of less than 0.4 gram,typically less than 0.2 gram. Indeed, even less than 0.05 gram lossesare obtainable. In addition, the percent yield of coating which remainson the popcorn after popping, relative to the amount of coating measuredon the uncoated kernels after coating and before any prepopped flakingloss, typically is at least about 60%. Figures of 65% and above readilyare obtainable.

In general, a 78 gram sample of coated popcorn made according to thepreferred methods described herein includes at least about 4.5 grams,typically and preferably at least 5.0 grams, and for some compositionsmore preferably at least 5.5 grams, of coating thereon. Thiscorresponds, in a 225 gram sample, to at least about 13.0 grams,preferably at least 14.4 grams of coating, and for some samples morepreferably at least about 15.9 grams.

It is noted that many of the preferred coatings described herein do notinclude any starch component. The particular manner in which the coatingis conducted, using low moisture and spray techniques, allows forapplication of the adhesive (for example, gums) to obtain a good coatingwith good properties and yield, without the need for starch. The coatingprocedure is also observed to provide for a relatively hard crust thatremains well fixed on the kernels, even during processing, and thus isadvantageous.

One of the advantageous features of processing according to the presentinvention is an efficient utilization of the flavoring. This can beassessed by considering the amount of flavoring which winds up adheredto the unpopped corn, versus the amount of flavor provided in the drymix that is applied to the unpopped kernels. In general, at least about80% of the flavorant (including salt) in the dry mix can be expected tobecome adhered to the unpopped kernels, utilizing techniques accordingto the present invention. Utilization of the preferred fine grind orpowdered salt described, facilitates this. Indeed, typically at leastabout 90% or more of the salt or other flavorant added, will be retainedon the unpopped kernels after the step of applying the dry flavor andblend to the unpopped kernels, when the preferred techniques describedare used.

B. The Tack or Adhesive Composition

The tack or adhesive composition for application to the kernelsgenerally should be aqueous-based and contain, preferably in solution,the desired adhesive.

A variety of tacking agents or adhesives may be used. Materials usableas the tacking agent comprise bacterial polysaccharide gums such asgellan gum, xanthan gum, gum arabic, and cellulose gum or mixturesthereof. By "bacterial" in this context, it is meant that the gumcomprises a product of a microorganism's operation on a fermentationmedium. For example, gellan gum is produced by the microorganismPseudomonas elodea (ATCC 31461). Xanthan gum comprises the fermentationproduct of Xanthomonas campestris. Gum arabic, also known as Gum acacia,is the dried gummy exudate from stems and branches of Acacia senegal(Linne), willdenow or other related African species of acacia. A useablecellulose gum is sodium carboxymethyl cellulose.

The presently preferred gum is gellan gum. Kelco K3B408 is a particularpreferred gellan gum for utilization in coating compositions forunpopped popcorn.

TIC Gums No-Fat Snack Blend is another preferred gum for utilization incompositions for application to unpopped popcorn. In certain preferredcompositions, exemplified below, mixtures of K3B408 and TIC Gums No-Fatblend will be most preferred.

In general, the solution should contain no more than an amount ofmoisture which is needed to provide a good distribution of the coatingover the kernels, and to maintain the adhesive material in solutionduring application. In the case of unpopped kernels, generally less than2%, and preferably about no more than 1.4%, of adhesive composition isapplied, by weight of popcorn, typically 0.5-1.2%. Indeed, only about1.12% of tacking solution (by weight raw kernel) is required forpreferred applications. The prepopped flakes discussed above, on theother hand, generally required at least about 4-6% tacking solution (byweight of popped flakes) to get preferred spread and adhesion to theuneven surfaces of the flakes (a preferred level being about 5.36%).

Preferably, the adhesive composition contains about 0.05-15%, by weight,adhesive. When the adhesive is gellan gum, preferably the solutioncontains about 0.05-1.0% by weight. When it is the TIC Gums No-Fatmaterial, it is preferably 9-15% by weight.

C. Flavorant and Adjuvants

As with the techniques described hereinabove for prepopped popcorn, inpreferred processing flavorants and adjuvants are added as a dry mix,sifted onto the kernels. The various flavorants described with respectto coating prepopped popcorn, may be used. Preferred compositions, forproviding a salt/butter flavor, are described hereinbelow, in anexample.

In general, it is again desired that the flavorants be provided inpowdered or finely ground form, or supported on a powder or fine grindbase, to achieve 50-250 U.S. standard mesh. Some flavorants can beprovided in the solution containing the adhesive, provide they are in aform that does not interfere with the application process (typically bymisting). Thus, preferably any such flavorants that are provided, areprovided dissolved in solution.

One adjuvant found useful in connection with applications according tothe present invention, to unpopped kernels, is silicon dioxide (SiO₂). Acommercially available silicon dioxide additive useable is Zeothix 265.In general, the silicon dioxide is observed to keep kernels for adheringto one another.

In general, the flavorants should be mixed dry for application bysifting, in a manner similar to the techniques described above withrespect to the prepopped popcorn. A flavorant sift of about 70-250 U.S.standard mesh will be preferred.

D. Application of the Tacking or Adhesive Solution to the Kernels

Preferably the tacking or adhesive solution is applied to the unpoppedpopcorn kernels in a manner that ensures even and thorough coating. Avariety of application techniques may be used, for example, spraying,ladling, etc. In general, for application by spraying, which ispreferred, what is required is a spraying arm with several nozzles,directed to apply the composition to kernels in a pan-type coater. It isnot required that the spray or mist be as fine as is preferred forcoating prepopped flakes.

In preferred processes, the kernels are rotated in a pan-type coaterwhile the spray is applied. The spray should be applied over about a oneto three minute time frame (preferably 1.5 to 2.0 minutes).

E. Application of the Flavoring Sift and Drying

The flavoring is sifted onto the wet kernels after the mist has beenapplied thereto, and while the kernels are tumbled in the coater. Thetumbling should be conducted until the powder is distributedsubstantially evenly.

Timing of drying is less critical than with popped flakes, becausekernels do not readily absorb water. However, in general, the excessmoisture will be dried from the coated kernels immediately afterapplication of the dry mix. The drying should preferably be conducteduntil a moisture level of between about 11% and 13% is obtained (i.e.the preferred moisture level of raw, uncoated, unpopped popcornkernels). Air temperatures from the heat source ranging from about 160°to 200° F. (forced heated air) will be preferred. Dry cycle times on theorder of about 3 to 16 minutes per 630 lb batch (typically containingabout 5 to 8 lbs of tacking solution) will be preferred.

Although unpopped kernels are not as susceptible to moisture damage asare popped kernels, in general it is desirable to apply as littlemoisture as is reasonably possible, in accomplishing the coating withthe adhesive material. A reason for this is that less energy well beneeded to drive off the moisture during the drying processes.

Thus, in general, as with the application of the prepopped popcorn, thefollowing three factors will typically be most controlling, in definingprocesses which are preferred.

1. The amount of water (or adhesive composition) applied per weight ofpopcorn, in conducting the initial coating.

2. The amount of adhesive applied per weight of popcorn, to achieve thedesired level of adhesiveness; i.e. achievement of an effective a mountof adhesive.

3. The rate of drying, to achieve a residual coating with a flavorantsecured thereto.

In addition, to have desirable handling characteristics, it is preferredthat the unpopped kernels be provided in a form such that they do notstick to one another during the processing, and so that they can beprocessed and handled without individual kernels knocking offsubstantial amounts of flavorant or coating, by bumping into oneanother. A factor of some significance with respect to this, is thefineness of the dry flavoring powder applied to the kernels, and theamount applied per weight of kernel. In general, it has been observedthat the coated kernels, of preferred products, comprise about 6.7% byweight coating.

For a salt-flavored formula, preferably at least about 2 gram of saltare applied per 100 gram of unpopped kernels.

EXPERIMENTAL

In the examples, footnotes are used to identify information about thevarious ingredients. Throughout the Experiments, these footnotes havethe following meanings:

¹ Spectrum Chemical, granular FCC (CA 138), Gardena, Calif.

² Less than 200 U.S.S mesh screen; Morton Salt, Chicago, Ill. 60606.

³ 70-240 U.S.S. mesh screen; Morton Salt, Chicago, Ill. 60606.

⁴ Chris Hanson's Laboratories, Milwaukee, Wis. 53214

⁵ Tastemaker, Cincinnati, Ohio 45216

⁶ Warner Jenkinson Co., St. Louis, Mo. 63178-4538

⁷ Chris Hanson's Laboratories, Milwaukee, Wis. 53214

⁸ Tastemaker, Cincinnati, Ohio 45216

⁹ Tastemaker, Cincinnati, Ohio 45216

¹⁰ 70-240 U.S.S. mesh screen; Morton Salt, Chicago, Ill. 60606

¹¹ Hoechst Celanese, Somerset, N.J. 08873

¹² Sanofi Bio-Industries, Inc., Fairfield, N.J. 07006

¹³ 70-240 U.S.S. mesh screen; Morton Salt, Chicago, Ill. 60606

¹⁴ Chris Hanson's Laboratories, Milwaukee, Wis. 53214

¹⁵ McCormick Flavor Division, Hunt Valley, Md. 21031

¹⁶ BBA Brown Sugar #35143; Bush Boake Allen, Inc., Chicago, Ill.60618-9131

¹⁷ Tastemaker, Cincinnati, Ohio 45216

¹⁸ Tastemaker, Cincinnati, Ohio 45216

¹⁹ Zeothix 265, J. M. Huber Corp., Etowah, Tenn. and Havre de Grace, Md.

²⁰ Grain Processing Corp., Muscatine, Iowa 52761

²¹ Bush Boake Allen, Inc., Chicago, Ill. 60618-9931

EXPERIMENT 1 Preparation of a Butter Flavor, Prepopped Popcorn

3.5 lbs. of popped flakes

85 grams of a K3B408 gellan gum--1% solution, as a tacking agent (i.e.83 grams of an aqueous solution of 1% K3B408 by weight)

    ______________________________________                                        Blend of dry flavorant, coloring and salts                                    Ingredient          Quantity (grams)                                          ______________________________________                                        Calcium chloride.sup.1                                                                            0.75                                                      Salt - Morton 200.sup.2                                                                           25.00                                                     Salt - Morton Flour.sup.3                                                                         77.22                                                     Encap. Starter Distillate - 50X.sup.4                                                             9.32                                                      Natural Butter Flavor.sup.5                                                                       13.05                                                     Yellow #5, alum. lake.sup.6                                                                       4.66                                                      Butter Flavor, NF.sup.7                                                                           20.00                                                                         150.00    grams                                           ______________________________________                                    

The 3.5 lb of popped flakes were obtained using a hot air popper. Beforethe coating step was conducted, the flakes were sifted to remove fineparticulates.

The adhesive composition comprised a 1% solution containing 85 g ofK3B408 gellan gum, in water.

The popped flakes were placed in the rotatable drum of a pan-typecoater. A fine mist was created from the gellan gum solution by a WagnerHeavy Duty paint sprayer set at finest setting. It was applied over thepopped flakes, while the drum was rotated to ensure a substantially evencoating.

The blend of dry flavorant was prepared. Immediately after the adhesivecomposition was applied to the popped kernels, the dry flavorant wassifted thereon using a common household sifter. During the sifting, thekernels were rotated to ensure even coverage. The dry flavorant mix wasapplied over a period of about 1 minute at ambient temperatures.

Immediately after the dry flavor was applied, the flakes were dried bywith a Varitemp heat gun set at 600° F. (Master Appliance Corp., Racine,Wis. 53403). The product had an acceptable taste and texture for aconsumer snack food.

EXPERIMENT 2 Cheese Flavor, Prepopped Popcorn

The same procedure as described in Experiment 1 was used. The componentswere as follows.

3.5 lbs. of popped flakes

40 grams of a K3B408 gellan gum--1% aqueous solution, plus 40 grams of aTIC Gums No Fat Snack Blend--9% aqueous solution as a tacking agent (Thetwo 40 gram solutions were applied one right after the other.)

    ______________________________________                                        Blend of dry flavorant, coloring and salts                                    Ingredient          Quantity (grams)                                          ______________________________________                                        Calcium chloride.sup.1                                                                            0.39                                                      Salt - Morton 200.sup.2                                                                           30.93                                                     Salt - Morton Flour.sup.3                                                                         50.00                                                     Encap. Starter Distillate - 50X.sup.4                                                             2.58                                                      Cheese Flavor, Buttery.sup.8                                                                      12.89                                                     Yellow #6, alum. lake.sup.6                                                                       3.22                                                      Cheese Flavor.sup.9 30.00                                                                         130.00    grams                                           ______________________________________                                    

The product has an acceptable taste and texture for a consumer snackfood.

EXPERIMENT 3 Sweetened, Prepopped Popcorn

The same procedure as for Experiment 1 was used. The components were asfollows.

3.5 lbs. of popped flakes

85 grams of K3B408 gellan gum--1% solution, tacking agent

    ______________________________________                                        Blend of dry flavorant, coloring and salts                                    Ingredient          Quantity (grams)                                          ______________________________________                                        Calcium chloride.sup.1                                                                            0.80                                                      Salt - Morton 200.sup.2                                                                           6.35                                                      Maltodextrin (M040).sup.10                                                                        79.38                                                     Sunette, acesulfone K.sup.11                                                                      0.45                                                      Sanofi, aspartame 200.sup.12                                                                      0.45                                                      Vanilla.sup.13      3.18                                                      Color, brown lake.sup.14                                                                          3.00                                                      Caramel flavor.sup.15                                                                             30.00                                                     Brown sugar flavor.sup.16                                                                         2.00                                                      Vanilla cream flavor.sup.17                                                                       2.00                                                                          127.61    grams                                           ______________________________________                                    

The product had an acceptable flavor and texture for a consumer snackfood. However, it is noted that this formulation does not provide for acandy glaze or coating appearance that is common in sweet popcornproducts.

EXPERIMENT 4 Provision of Flavor-Containing Coating on Unpopped Kernelsfor Microwave Popping

For this experiment the tackifying composition comprised 5 lbs of anaqueous based mixture containing 0.7% by weight Kelco gel K3B408. Thistackifying composition was added to 600 lb. raw kernels, in a pan-typecoater over a period of 1-2 minutes.

The dry blend comprised 21 lb. Morton Salt 200 (in an alternate, 16 lbof Morton Salt 200 were used) with 4.6 lb of a mixture containing: 1 lb.Tastemaker Peanut Flavor 307777; 3 lb. Tastemaker Corn Flavor 316176;and 0.6 lb. Chris Hanson's Encapsulated Starter Distillate 50X. The dryblend was sifted onto the kernels, immediately after the tackifyingcomposition had been applied thereto. The mixture was rotated for1.5-2.0 minutes to evenly disperse the dry ingredients. The applicationwas done in a pan-type coater at ambient temperatures (60°-80° F).

After the dry blend was applied, the air drying system was started todry off the excess moisture (5-15 minutes at 160°-200° F). The coatedkernels were dried down to a 11.5-13% moisture content, by weight.

Both formulations provided a material that, when popped, had anacceptable flavor and texture for a consumer product.

EXPERIMENT 5 Provision of Flavor-Containing Coating on Unpopped Kernelsfor Microwave Popping

The same procedure as for Experiment 4 was used. The components were asfollows.

    ______________________________________                                        Ingredient          Quantity                                                  ______________________________________                                        Raw popcorn         600.00      lbs                                           Tacking solution (0.7% solution                                                                   7.00        lbs                                           of K3B408) (Alternatively 9-12%                                               solution of TIC No Fat Snack                                                  blend could be used.)                                                         Dry blend:                                                                    Morton salt 200.sup.2                                                                             25.00       lbs                                           (22.5 lbs are generally                                                       preferred.)                                                                   Encap. Starter Distillate - 50X.sup.4                                                             5.17        lbs                                           Tastemaker #264904 - Butter                                                                       1.59        lbs                                           Flavor.sup.18                                                                 Silicon dioxide.sup.19                                                                            200.00      grams                                         ______________________________________                                    

The resulting product was a material which, when popped, had anacceptable flavor and texture for a consumer product.

EXPERIMENT 6 Provision of Flavor-Containing Coating on Unpopped Kernelsfor Microwave--Sweet Version

The following formulation, it is believed, would provide for a materialthat could be popped to an acceptable sweet popcorn product. A proceduresimilar to Experiment 4 could be used.

    ______________________________________                                        Ingredient            Quantity                                                ______________________________________                                        Raw popcorn           600.00    lbs                                           Tacking solution (0.7% solution                                                                     4.00      lbs                                           of K3B408) (Alternatively a 9-14 12%                                          solution of TIC No-Fat Snack blend                                            could be used)                                                                DRY BLEND:                                                                    Calcium Chloride      0.05      lbs                                           BBA Butterscotch Flv. #41025.sup.21                                                                 3.0       lbs                                           BBA Brown sugar #35143.sup.16                                                                       0.5       lbs                                           Chris Hanson's Encapsulated                                                                         0.7       lbs                                           Starter Distillate 50X                                                        Maltodextrin (M-10 Maltrin).sup.20                                                                  0.5       lbs                                           Silicon dioxide (Zeothix 265)                                                                       200.0     grams                                         ______________________________________                                    

EXPERIMENT 7 Prepopped Flaking

Herein the term "pre-popped flaking" is used to refer to the amount ofcoating likely to be lost during handling, but prior to popping.

The equipment used is as follows:

1. Tumbler plus stainless steel canister (INDCO tumbler No. RM101;,INDCO, INC., New Albany, Ind.) (115 V; 60 HZ; 0.54 amp.).

2. Balance (accurate to 0.01 amp).

3. Timer.

In general, the procedure used for the assessment of the coating was asfollows:

An approximately 225 gram sample of the coated unpopped popcorn to beassessed was isolated and weighed, to 0.01 gram (INITIAL WT). The samplewas poured into the tumbler canister (depth 10 cm.; diameter 8.5 cm.).The canister was rotated (about a generally horizontal axis) in thetumbler for one hour at ambient temperature (or revolutions perminute--rpm). The entire contents of the tumbler canister were pouredonto a No. 12 sieve. Any residue that may have fallen off the corn inthe tumbler was collected. The sieve was tapped 50 times by hand (abouta 1 inch, gentle, tap), to ensure that all loose flaking was separatedfrom the kernels. The kernels of coated corn were then weighed (FINALWT). The difference (Pre-Popped Flaking) reflected the amount offlaking, or loss of coating, before or during the tumbling but prior topopping. Greater amounts of flaking or loss are reflective of a lessdesirable product, since the coating would have a greater propensity toflake off the kernel during processing, packaging the corn, or inhandling prior to popping.

Results for the tests are reported in Table I below. Sample preparationis described hereinbelow.

                  TABLE I                                                         ______________________________________                                                                        Pre-Pop                                                Initial Wt.   Final Wt.                                                                              Flaking                                       Sample   (g)           (g)      (g)                                           ______________________________________                                        1        225.04        225.04   0.00                                          2        224.96        224.96   0.00                                          3        224.95        224.95   0.00                                          4        224.01        224.99   0.02                                          ______________________________________                                    

Sample ID

Samples 1 and 2 were made according to the process of Experiment 4except using: 6.0 lbs of 9.0% TIC Gum No-Fat snack blend as theadhesive; and, a dry mix of lbs of Morton Salt 200, 5.17 lbs ofEncapsulated Starter Distillate-50X, and 1.59 lbs of Butter Flavor#264904, as the dry blend.

Samples 3 and 4 were made according to the process of Experiment 4except using: 6.0 lbs of 0.8% K3B408 solution as the adhesive; and, adry mix of 25 lbs of Morton Salt 200, 5.17 lbs. of Encapsulated StarterDistillate-50X and 1.59 lbs of Butter Flavor #264904 as the dry blend.

EXPERIMENT 9 Evaluation of Amount of Coating Put on Unpopped Kernels byEach Process

In order to determine a percentage coating retention, it is necessary toevaluate how much coating is initially applied to each sample. This wasdone by washing down each sample with a washdown method described below.For the experiment, 78 gram samples of coated popcorn material wereused.

The Washdown Method

Equipment:

Electronic Sale

Moisture Analyzer (Computrac Max. 50; from Arizona Instruments, Inc. ofPhoenix, Ariz.)

Mill (Cemotec 1090 Sample Mill, Manufactured by Tectator, Hoganes,Sweden; obtained from Fisher Scientific)

2-500 ml Erlenmeyer flasks

Sieve (No. 12--1.70 MM)

Heat gun (Master Appliance Corp., Racine, Wis. 53403)

For each formulation evaluated, two 78 gram samples of the coatedpopcorn were collected and isolated. For each 78 gram sample, ameasurement of the amount of coating by the washdown technique was used.Also a measurement of the amount of moisture on uncoated corn was made.Moisture measurements were made by grinding a small portion of sample inthe mill, at the finest grind setting, and then analyzing in themoisture analyzer. This was done on raw corn and also on samples afterwashing and drying.

The procedure was as follows:

1. Weigh out two 78 gram samples of the selected formulation of coatedcorn to be evaluated. Record the weight (in grams) of the samples to thehundredths place.

2. Determine moisture level of raw (uncoated) corn, with moistureanalyzer.

3. Pour each coated corn sample into separate 500 ml flasks.

4. Pour 200 gram of tap water (100° F.+/-3° F.) over each of the samplesof coated corn in the flasks, and swirl for 3 minutes.

5. Pour each washed sample into a No. 12 sieve that will retain thekernels. Gently tap the sieve 10 times, to remove excess moisture. Pouronto a tray to dry.

6. Dry with a hand held heat gun for approximately 2 minutes, keepingthe air temperature over the corn at about 100°-115° F. Shake the trayto keep the kernels rolling onto different sides during the drying. Itis important not to overdry the corn. Continue drying should beconducted at about 90° F. for about 20 minutes. At that time, themoisture content of the washed sample will be about the same as themoisture content of the raw corn. This was confirmed with the analyzer.

7. The amount of coating is determined by subtracting the initial weightof sample (weight to the hundredths) from the wash/dried weight of thesame sample.

The formulations evaluated were as follows:

Sample 1: As stated above for Sample 1 in TABLE I.

Sample 2: As stated above for Sample 2 in TABLE I.

Sample 3: As stated above for Sample 3 in TABLE I.

Sample 4: As stated above for Sample 4 in TABLE I.

The data is reported in Table II.

                  TABLE II                                                        ______________________________________                                        Sample    Wt. of Coating in 78 g Sample                                       ______________________________________                                        1         5.64 g                                                              2         5.60 g                                                              3         5.48 g                                                              4         5.28 g                                                              ______________________________________                                    

                  TABLE III                                                       ______________________________________                                        Subtract amount of pre-popped flaking                                         that occurs after preparation and                                             one hour of tumbling (from Table I)                                                    Wt. Coating - Pre-Popped Flaking                                     Sample   (per 78 g Sample)                                                    ______________________________________                                        1        5.64 - 0.00 = 5.64                                                   2        5.60 - 0.00 = 5.60                                                   3        5.48 - 0.00 = 5.48                                                   4        5.28 - 0.01.sup.1 = 5.27                                             ______________________________________                                         .sup.1 The value of 0.01 was obtained by adjusting the value of 0.02          obtained for a 225 g sample to the amount of loss which would occur for a     78 gram sample  i.e., (78/225) × 0.02 - .007 (rounded to .01).     

EXPERIMENT 10 Post-Popped Flaking and Final Yield

To evaluate final yield on the popcorn as it would be when consumed,each sample was popped, and the amount of post-popped flaking wasmeasured. Herein the term "post-popped flaking" refers to the amount ofcoating loss which occurs during popping and not during pre-poppedhandling. For the post-popping flaking test, three samples for eachformulation were used and the values were averaged. Two of the samplesused for each formulation were the two samples from the pre-poppedflaking test described above. That is, they were the two samplesevaluated for pre-popped flaking loss. The third sample in each instancewas a sample from the same formulation that had not been evaluated forpre-popped flaking according to the procedure above. The data isreported in Table IV.

In each instance, for the post-popped flaking, the approximately 78 gramsample was placed in an 11.25 inch popping bag, and popped for 2 minutes25 seconds in a Kenmore microwave oven. No oil/fat or other additiveswere used. The popped volume was determined, for each sample, by puttingthe popcorn into a 4000 ml graduated cylinder and gently shaking tolevel the material.

                  TABLE IV                                                        ______________________________________                                        Values from TABLE III minus amount of                                         post-popped flaking that occurs after popping,                                i.e., amount of coating remaining after popping                                        Amount of Coating Remaining After                                    Sample   Popping (per 78 g Sample)                                            ______________________________________                                        A        5.61.sup.1 - 1.23.sup.2 = 4.39 g                                     B        5.38.sup.3 - 1.30.sup.4 = 4.08 g                                     ______________________________________                                         .sup.1 The value of 5.62 is the average of 5.64 and 5.60, ie., samples 1      and 2 above.                                                                  .sup.2 The value of 1.23 is an average of 3 value (1.30, 1.23 and 1.17).      .sup.3 The value of 5.38 is an average of 5.48 and 5.27, the two values       obtained for samples 3 and 4 above, i.e, made according to samples 3 and      4.                                                                            .sup.4 The value of 1.30 is the average value of three figures (1.37, 1.2     and 1.33).                                                               

With respect to Sample A, of the three values averaged, the first two(1.30 and 1.23) were values for the samples that had been subjected tothe pre-popped flaking test. The third value (1.17) was measured frommaterial made in the same batch, but not tested for pre-popped flaking.The popped volumes for the three samples were 2850, 2700 and 2775,respectively.

With respect to Sample B, of the three values averaged for pre-poppedflaking, the first two (1.37 g and 1.20 g) were for the materials testedfor pre-popped flaking. The third value averaged (1.33 g) was for asample of the same material which had not been subjected to thepre-popped flaking evaluation. The popped volumes for the three sampleswere 2750, 2800 and 2850, respectively.

                  TABLE V                                                         ______________________________________                                        AVERAGE PERCENT OF COATING RETENTION (YIELD)                                  (amount of coating on final popcorn)                                          (Amount inititially present on unpopped kernels)                                     Sample                                                                              Percentage                                                       ______________________________________                                               A     78.1%                                                                   B     75.7%                                                            ______________________________________                                    

What is claimed is:
 1. A method for applying a flavoring composition topopped popcorn; said method including the steps of:(a) applying anaqueous-based adhesive composition onto popped popcorn; saidaqueous-based adhesive composition including a flavoring adhesiveeffective amount of adhesive agent; and having no added fat or oiltherein; and (b) after said step of applying, applying dry flavorantcomposition onto the popped popcorn; and (c) drying excess moisture fromthe popped popcorn.
 2. A method according to claim 1 wherein:(a) saidstep of applying adhesive composition comprises applying theaqueous-based adhesive composition as a fine mist.
 3. A method accordingto claim 2 wherein:(a) said step of spraying comprises applying aadhesive composition containing about 0.5-15% by weight adhesive.
 4. Amethod according to claim 3 wherein:(a) said step of spraying comprisesapplying about 1-10% by weight adhesive composition, per weight ofpopped popcorn.
 5. A method according to claim 4 wherein:(a) said stepof applying dry flavorant composition comprises applying a drycomposition of 50-250 mesh U.S. Standard.
 6. A method according to claim5 wherein:(a) said dry flavorant composition includes salt as aflavorant; and (b) said step of applying dry flavorant compositionincludes applying at least 100 g of salt per 1500 g of popped popcorn.7. A method according to claim 1 wherein:(a) said step of drying isconducted to achieve a moisture level of no greater than about 2% byweight.
 8. A popcorn product comprising the result of:(a) spraying anaqueous-based adhesive composition onto popped popcorn; saidaqueous-based adhesive composition including a flavoring adhesiveeffective amount of adhesive agent; and having no added fat or oiltherein; and (b) after said step of spraying, applying dry flavorantcomposition onto the popped popcorn; and (c) drying excess moisture fromthe popped popcorn.